System And Method Of Assembling And Installing Commercial Roofing

ABSTRACT

A system for assembling roofing at ground level has an adjustable-length center frame separating a first assembly side from a second assembly side; a first cantilevered gantry on the first assembly side and a second cantilevered gantry on a second side, each cantilevered gantry moveable along the length of the center frame; a plurality of outrigger beams coupled to opposing ends of the center beam, each outrigger beam having a catwalk thereon; a first joist railing and a second joist railing on each assembly side, each joist railing configured to receive an end of an open web joist; and a base frame comprising a plurality of wheels. Once the roofing section has been assembled, hoisting the assembled roofing section to the top of a structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 62/421,448 filed on Nov. 14, 2016 and U.S. Provisional ApplicationSer. No. 62/550,855, filed on Aug. 28, 2017, both of which areincorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to commercial construction. Moreparticularly, the present disclosure relates to a system and method ofassembling roofing components at ground level and installing theassembled roofing components on a structure.

BACKGROUND

Building construction is an inherently dangerous activity. Heavymaterials, large equipment, and heights all create added risk. This isparticularly true for the roofing industry. When installing roofing, itis not uncommon to have many workers on the roof level, where they areinteracting with dangerous components at dangerous heights. The moreworkers on the roof, the higher the odds of an accident. In an effort toreduce these risks, safety measures have been implemented for thoseworkers on the roof, such as safety harnesses. However, while the riskis lowered by using safety harnesses and equipment, accidents stilloccur. Further, such safety measures slow the process of roofinstallation, as each construction worker on the roof must ensure thatthe appropriate safety measures are completed. This may includereleasing a first strap while relocating to the next position, thensecuring a second strap. If only one strap is used, the user risksfalling when relocating to a new position on the roof. Both of thesemeasures take time and thereby reduce efficiency. Further, equipmentmust be hoisted to those workers on the roof. Cranes or other deviceslift such materials, where they interact dangerously with the men on theroof. Accordingly, to assemble a typical commercial roof, severalworkers are needed at roof height to help position open web joists,place sheathing, perform welding, etc. In other words, in order to workquickly, a greater number of workers is needed on the roof. However, asstated earlier, the more workers on the roof, the higher the odds of anaccident.

Therefore, there remains a need for a system whereby the risks of roofinstallation are reduced, while the efficiency of assembling andinstalling the roof increases. The present invention seeks to solvethese and other problems.

SUMMARY OF EXAMPLE EMBODIMENTS

A system for assembling roofing comprises an adjustable-length centerframe separating a first assembly side from a second assembly side; afirst cantilevered gantry on the first assembly side and a secondcantilevered gantry on a second side, each cantilevered gantry moveablealong the length of the center frame; a plurality of outrigger beamscoupled to opposing ends of the center beam, each outrigger beam havinga catwalk thereon; a first joist railing and a second joist railing oneach assembly side, each joist railing configured to receive an end ofan open web joist; and a base frame comprising a plurality of wheels.

A method of assembling roofing using a system for assembling roofingcomprises placing a plurality of open web joists between the first joistrailing and second joist railing of the first assembly side; placing aplurality of open web joists between the first joist railing and secondjoist railing of the second assembly side; mounting and welding thepurlins of the open web joists; placing a bunk of corrugated steelsheathing on the first cantilevered gantry; moving the firstcantilevered gantry along the length of the center frame; removingsheets of corrugated steel sheathing from the first cantilevered gantryas it travels on the center frame; securing the corrugated steelsheathing to the open web joists, forming an assembled roofing section;hoisting the assembled roofing section to the top of a structure forsecuring thereto.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a system for assembling roofing;

FIG. 2 is a perspective view of a system for assembling roofing;

FIG. 3 is a perspective view of a system for assembling roofing;

FIG. 4 is a perspective view of a system for assembling roofing;

FIG. 5 is a perspective view of an assembled roofing section beingplaced on a roof;

FIG. 6 is a perspective view of an outrigger beam of a system forassembling roofing;

FIG. 7 is a perspective view of a center frame of a system forassembling roofing;

FIG. 8 is a perspective view of a system for assembling roofing stackedfor transportation;

FIG. 9 is a perspective view of a system for assembling roofing stackedfor transportation;

FIG. 10 is a perspective view of a cantilevered gantry of a system forassembling roofing;

FIG. 11 is a side detailed view of a cantilevered gantry of a system forassembling roofing; and

FIG. 12 is a motor-driven wheel of a system for assembling roofing.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The following descriptions depict only example embodiments and are notto be considered limiting in scope. Any reference herein to “theinvention” is not intended to restrict or limit the invention to exactfeatures or steps of any one or more of the exemplary embodimentsdisclosed in the present specification. References to “one embodiment,”“an embodiment,” “various embodiments,” and the like, may indicate thatthe embodiment(s) so described may include a particular feature,structure, or characteristic, but not every embodiment necessarilyincludes the particular feature, structure, or characteristic. Further,repeated use of the phrase “in one embodiment,” or “in an embodiment,”do not necessarily refer to the same embodiment, although they may.

Reference to the drawings is done throughout the disclosure usingvarious numbers. The numbers used are for the convenience of the drafteronly and the absence of numbers in an apparent sequence should not beconsidered limiting and does not imply that additional parts of thatparticular embodiment exist. Numbering patterns from one embodiment tothe other need not imply that each embodiment has similar parts,although it may.

Accordingly, the particular arrangements disclosed are meant to beillustrative only and not limiting as to the scope of the invention,which is to be given the full breadth of the appended claims and any andall equivalents thereof. Although specific terms are employed herein,they are used in a generic and descriptive sense only and not forpurposes of limitation. Unless otherwise expressly defined herein, suchterms are intended to be given their broad, ordinary, and customarymeaning not inconsistent with that applicable in the relevant industryand without restriction to any specific embodiment hereinafterdescribed. As used herein, the article “a” is intended to include one ormore items. When used herein to join a list of items, the term “or”denotes at least one of the items, but does not exclude a plurality ofitems of the list. For exemplary methods or processes, the sequenceand/or arrangement of steps described herein are illustrative and notrestrictive.

It should be understood that the steps of any such processes or methodsare not limited to being carried out in any particular sequence,arrangement, or with any particular graphics or interface. Indeed, thesteps of the disclosed processes or methods generally may be carried outin various different sequences and arrangements while still fallingwithin the scope of the present invention.

The term “coupled” may mean that two or more elements are in directphysical contact. However, “coupled” may also mean that two or moreelements are not in direct contact with each other, but yet stillcooperate or interact with each other.

The terms “comprising,” “including,” “having,” and the like, as usedwith respect to embodiments, are synonymous, and are generally intendedas “open” terms (e.g., the term “including” should be interpreted as“including, but not limited to,” the term “having” should be interpretedas “having at least,” the term “includes” should be interpreted as“includes, but is not limited to,” etc.).

As will be appreciated from this disclosure, the present system andmethod for assembling a commercial roof significantly reduces risk toworkers by allowing the majority of workers to remain at ground level.In other words, the roof is assembled in sections at the ground level,allowing most workers to remain at ground level as part of the assemblyteam. Only two workers are required to be on the roof for finalplacement of the assembled roofing sections, which significantly reducesthe odds of someone falling. Further, because the roof is assembled atground level, workers are able to work more efficiently. In other words,workers at ground level do not need to concern themselves with beingsecured to the structure and working under such constraints. As such,workers are able to move around more freely and quickly, allowing forfaster assembly of roof sections.

In one embodiment, as shown in FIGS. 1-4, a system for assemblingroofing 100 comprises a center frame 102 separating a first assemblyside 104 from a second assembly side 106; a first cantilevered gantry108 on the first assembly side 104 and a second cantilevered gantry 110on a second assembly side 106, each cantilevered gantry 108, 110moveable along the length of the center frame 110; a plurality ofoutrigger beams 112A-112D coupled to opposing ends of the center beam102, each outrigger beam 112A-112D having a catwalk 114A-114D thereon; afirst joist railing 116 and a second joist railing 118 on a firstassembly side 104 and a first joist railing 120 and a second joistrailing 122 on a second assembly side 106, each joist railing 116, 118,120, 122 configured to receive an end of an open web joist 129 (as bestshown in FIG. 2); and base frame members 124 comprising a plurality ofwheels (or casters) 126. Each joist railing 116, 118, 120, 122 comprisesjoist receiving brackets 128. The brackets may be placed at a pluralityof positions along the joist railings 116, 118, 120, 122 so as to complywith the relevant blueprint requirements for joist spacing. Therefore,in one example of use, the workers would place a plurality of open webjoists 129 between joist railings 116 and 118, with each end of the openweb joist 129 being received in receiving brackets 128. This is easilyaccomplished by having a worker on each catwalk 114A, 114B guiding thejoist 129 into the receiving brackets 128 as a joist is hoisted intoplace. The same process is repeated on the second assembly side 106. Itwill be appreciated that the center frame 102 may be adjusted in length(either telescopically, by adding additional segments, or similarextending means, or simply using a longer center frame) so that joistsof varying lengths, according to the job at hand, may be used. It willbe appreciated that while open web joists 129 are used as examplesthroughout this disclosure, the invention is not so limited, and otherjoists and roofing structures may be used.

As shown in FIG. 2, with the joists 129 placed in the receiving brackets128, the purlins 130 may be easily mounted and welded. In this example,a fully assembled roofing section 136 is being hoisted by a crane to beplaced on a roof, while the workers are assembling a second roofingsection on the other assembly side. A forklift 132 or other machinerymay hoist a bunk of corrugated steel sheathing 134 onto the firstcantilevered gantry 108. The first sheets of corrugated sheathing 134may then be placed on top of the joists 129, with the workers moving thefirst cantilevered gantry 108 as each sheet of corrugated sheathing 134is placed. The first cantilevered gantry 108 may be moved manually, suchas by a user pushing it, or using a motor or other linear actuator(e.g., hydraulics, motor-driven screw drives, etc.). As shown in FIGS.3-4, as the first cantilevered gantry 108 moves along the center frame102 to the second end of the center frame 102, all of the corrugatedsheathing 134 is placed on the joists 129. The corrugated sheathing 134may then be secured to the joists 129. With the joists 129 weldedtogether with purlins 130 and the sheathing 134 secured to the top ofthe joists 129, the assembled roofing section is complete and ready forhoisting. FIG. 2 illustrates an assembled roofing section 136 beinghoisted by a crane 138 to the top of a structure. FIG. 5 illustrates theassembled roofing section 136 being positioned on the roof so that itmay be secured thereto. While not shown, a crane is typically supportingthe assembled roofing section while workers position it accordingly.Therefore, as will be understood, most of the roofing workers remain onthe ground level, using the system to construct assembled roofingsections. Accordingly, as few as two workers are needed on a rooftop forpositioning and securing the assembled roofing section. These are majoradvantages over the prior art. Further, because the system comprises tworoof assembly sides 104, 106 that are mirror images of each other, twoassembled roofing sections may be constructed simultaneously, allowingfor fast and efficient construction of the roof. For example, FIG. 4illustrates that while one assembled roofing section is near completion,joists 129 are being placed on a second assembly side to build itsimultaneously.

FIG. 6 illustrates a detailed view of an outrigger beam 112B. The joistreceiving brackets 128 are positionable on first joist railing 116, suchas by using bolts to secure the receiving brackets 128 to the railing116. The platform 114A provides a stable and secure environment for aworker to walk while placing and securing the receiving brackets 128 andthe joists 129 (not viewable in this Fig.) in the brackets 128.

FIG. 7 illustrates a detailed view of the center frame 102. As shown,the frame comprises an upper beam 142 on support legs 144, with lowerbeams 146, 148 for coupling to additional framing members as well asoutrigger beams (neither of which are visible in this Fig.). A generator140 may be mounted thereon to aid in welding and/or moving the system.In one embodiment, a system for assembling roofing comprises a generator140 which has electrical leads powering a welder feeder mounted to arotating post. The rotating post has an articulating arm which carriesthe welder feeder whip and welder gun. This allows a user to navigateboth assembly sides 104, 106 easily so as to perform required welding(e.g., purlins).

FIGS. 8-9 illustrate how the system for assembling roofing 100 isstackable so as to be easily transported. Accordingly, the entire systemmay be transported on standard roads without oversize equipment.

FIG. 10 is a detailed view of a cantilevered gantry 108. A supportgusset 150 rests on, and engages, via upper wheels 152, the upper beam142 of the center frame 102. Lower wheels 154 and roller bushings 156 atthe bottom of gantry support 158 engage the lower beams 146, allowingthe cantilevered gantry 108 to easily slide on the center frame 102.

FIG. 12 illustrates a detailed view of a motorized-wheel 160 for usewith the system of assembling roofing. As roofing is hoisted intoposition, the system may need to move forward to allow room for thecrane to lift the next assembled roofing section into place.Accordingly, a plurality of motorized-wheels 160 may be used. In oneembodiment, as shown in FIG. 1, the motorized wheels 160 are coupled to,and support, center frame 102. A motor 162 drives a plurality ofsprockets 164, 166 (using a chain, not shown) to actuate the tire 168.

As understood from the foregoing, the configuration of the system allowsthe workers to assemble a roofing section at ground level. As notedabove, and as shown in the drawings, there are two assembly sides 104,106. This increases efficiency by allowing one roof section to beassembled while another is being raised to position. As such, the secondassembly side 106 is a mirror image of the first assembly side 104.However, having two assembly sides 104, 106 is not required, although itis beneficial.

Exemplary embodiments are described above. No element, act, orinstruction used in this description should be construed as important,necessary, critical, or essential unless explicitly described as such.Although only a few of the exemplary embodiments have been described indetail herein, those skilled in the art will readily appreciate thatmany modifications are possible in these exemplary embodiments withoutmaterially departing from the novel teachings and advantages herein.Accordingly, all such modifications are intended to be included withinthe scope of this invention.

What is claimed is:
 1. A system for assembling roofing, comprising: a center frame separating a first assembly side from a second assembly side; a first cantilevered gantry on the first assembly side and a second cantilevered gantry on a second side, each cantilevered gantry moveable along the length of the center frame; a plurality of outrigger beams coupled to opposing ends of the center beam, each outrigger beam having a catwalk thereon; a first joist railing and a second joist railing on each assembly side, each joist railing configured to receive an end of an open web joist; and a base frame comprising a plurality of wheels.
 2. The system of claim 1, further comprising a generator.
 3. The system of claim 2, further comprising an articulating arm configured to carry a welder feeder whip and welder gun.
 4. The system of claim 1, wherein the components are stackable for transportation.
 5. The system of claim 1, further comprising motorized wheels coupled to, and supporting, the center frame.
 6. A method of assembling roofing using the system of claim 1, the method comprising: placing a plurality of open web joists between the first joist railing and second joist railing of the first side; placing a plurality of open web joists between the first joist railing and second joist railing of the second side; mounting and welding the purlins of the open web joists; placing a bunk of corrugated steel sheathing on the first cantilevered gantry; moving the first cantilevered gantry along the length of the center frame; removing sheets of corrugated steel sheathing from the first cantilevered gantry as it travels on the center frame; securing the corrugated steel sheathing to the open web joists, forming an assembled roofing section; hoisting the assembled roofing section to the top of a structure for securing thereto.
 7. The method of claim 6, further comprising a motor to move the cantilevered gantry along the center frame.
 8. A system for assembling roofing, comprising: a center frame having an assembly side; a cantilevered gantry on the assembly side; the cantilevered gantry moveable along the length of the center frame; two outrigger beams coupled to the center beam, each outrigger beam having a catwalk thereon; and a first joist railing and a second joist railing on the outrigger beams, each joist railing configured to receive an end of a joist. 